Discussion on Safety Management of Fertilizer Production Process

Red Phosphorus Company Quality, Safety and Environmental Protection Department Gui Weidong

The fertilizer production process has the characteristics of high continuity, complicated process, strict control of process parameters, and the production process is carried out in the state of high temperature, high pressure, low temperature and negative pressure. Raw materials and intermediate products used in production. , there are products such as flammable, explosive, toxic, corrosive and so many risk factors, ammonia production, especially the production of sulfuric acid dangerous, especially ammonia open parking takes a long time and consume too great. Plus some companies behind the technology, incomplete or defective safety equipment, the lack of the most basic aspects of the control support capabilities, as well as design, equipment and so on itself also varying degrees of defects, risks, etc., to bring a certain degree of process safety management difficulty. Operational accidents due to poor management of process safety technology or operational errors and other causes (accidents process) not uncommon in the reality of the production process, resulting in great economic losses to the enterprise, on a million small, a few million, as hundreds of large The direct economic loss of 10,000 yuan, how can such enterprises talk about economic benefits? Often negative impact of the process is not as personal injury accident caused the accident, and therefore senior managers are not aware of its severity. For the survival and development of the company, I would like to ask the top managers to pay attention to the process safety technology management in the process of chemical fertilizer production, and carefully analyze why the production cost is high and the production is always abnormal. I want to develop the process safety technology management foundation. It is not a problem to do a solid work, effective process operation and strict control indicators to achieve the operation of the device "safe, stable, long, full, excellent" and maximize the device capacity.

1. Strong training and education to improve the level of operation. When it comes to training, I think everyone knows it, but it is to educate employees. Actually, it is not a simple matter to achieve training results. First of all, we must pay attention to the training objects. Many senior managers mentioned that when training and education, they often only think of post operators. In fact, this kind of thinking is one-sided. Training and training for post operators is absolutely indispensable, but more importantly, Managers, technicians, and production commanders at all levels must also receive comprehensive education and training in strict safety technology and process technology to achieve the "three understandings and four meetings." Familiar with all aspects of the production process, in the inspection process can find problems or hidden dangers in time, and can propose solutions and preventive measures. The risk factors are accompanied by production. Production is the premise of the existence of risk factors. If there is no production, these risk factors will naturally disappear. Accidents can be avoided and reduced during the production process. Accidents can be avoided or reduced, that is, accident damage and losses are minimized, so as to achieve the expected goal of safe and civilized production. Safe and civilized production can bring vitality and vitality to enterprises. ,benefit. Secondly, the ability to deal with emergency response capabilities or emergencies is also an essential training component. Before the equipment is put into trial production operation, the enterprise shall prepare a chemical accident emergency treatment plan and train the personnel at all levels. The qualified units shall also conduct simulation exercises so that all levels of personnel know how to deal with emergencies and gradually Improve the emergency response capabilities of personnel at all levels. Once again pay attention to training methods, training methods should be flexible namely intensive classes, hands-on training, "sent out, please come in," in the form of classes before the class after the meeting, post the answer cards, no matter in what way the training, but be sure to pay attention to the effect. As a training manager, we must have a high degree of responsibility, be responsible to the company, be accountable to the operators, and must not go through the field. We must seriously organize the training to achieve the desired effect of the training. The degree to which the manager should understand the meaning of the training will affect the quality of the training. If the operator is not trained, he will arrange for independent operation, which violates the Labor Law, the Safety Production Law and the Occupational Disease Prevention and Control Law. Other laws and regulations are also prone to accidents due to unskillful operation and lack of basic safety knowledge. Therefore, strengthening training and education is the basic premise for the safe management of chemical fertilizer production process, and it is a crucial link.

2. Develop scientific and rigorous process procedures, job operation methods and safety technical regulations. Each production unit must have a corresponding process specification, post operation method and safety technical regulations before it is put into trial production, and must meet the safety requirements while ensuring production. When introducing new processes or changing process conditions, it must be reviewed and approved by the person in charge of the technical management department (or chief engineer of the process), and the procedures such as the operation method must be revised, and the effective version should be printed to each production position in time to guide Production operations. No one may change the process specifications without approval, and may not perform experimental operations on the equipment. It is necessary to be serious about the technical procedures, otherwise it is difficult to ensure safe and civilized production.

3. Strict process discipline ensures safe production. Strengthen the supervision and inspection of the implementation of process indicators, strict process discipline, strict requirements for operators, strengthen the education of process discipline, and gradually improve the consciousness of observing discipline. In the production process, it is carefully operated according to the process rules and operation methods, and the changes of temperature, pressure, flow rate, trace elements and other indicators in production are strictly monitored. At the same time, the coordination between the posts is strengthened, and the process indicators are never allowed to be large. Fluctuations, not allowed to over temperature, overpressure, overload operation. Importantly, if the safety process parameters are out of control, it will lead to irreparable consequences. Therefore, production commanders and post operators at all levels are required to stick to their posts and strengthen the monitoring of changes in process indicators. In the event of an abnormality, it is necessary to adjust in time and take effective measures to save the risk.

4. Take intrinsic safety measures to ensure safe operation of the unit. Safety monitoring devices are installed on key devices to improve operational safety, such as safety devices, liquid level alarms, flammable gas monitoring alarms, and interlock protection devices. In normal times, it is necessary to strengthen maintenance and inspection, and find that abnormal faults should be eliminated in time to ensure that they are in good condition and sensitive.

5. Safety evaluation of process indicators. There are many process indicators in the production process, it is difficult to control each index. Therefore, all process indicators are classified and managed. According to the size or danger of accidents caused by out-of-control process indicators, safety process indicators are classified. Targeted management. Because not every process indicator is out of control, it will cause accidents. Some of the process indicators out of control only affect the product quality, and will not involve personal equipment safety. However, if some process indicators are out of control, it will lead to major accidents, that is, equipment damage, production stoppage or casualties. Key safety process indicators like this should be listed as key monitoring targets. The management scope of the process index is divided and managed again. For example, the control range of a certain safety process index is divided into three areas, namely, the normal operation control area A-B, the dangerous control area C-D, the accident area E and above. In the production process, once the safety process indicators are found to fluctuate into the hazardous area, they should be adjusted in a timely and decisive manner. Otherwise, entering the accident area may lead to an accident. In addition, risk analysis and evaluation of important safety process indicators, which indicators have high probability of out of control, which indicators are out of control probability; which indicators are out of control risk, which indicators are out of control risk is small or general; through careful analysis and evaluation of safety process indicators, find Take the key points or weak links of process safety management and take effective measures to ensure the safe operation of the device.

6. Evaluation and analysis of process (operation) accidents. Due to poor process safety management or accidents caused by operational errors, and the resulting accident losses can not be compared with personal injury accidents, the process (operational) accidents are analyzed and evaluated according to the principle of accident handling. The cause of the accident, the development of accident prevention measures to eliminate or reduce accident losses. As the production management department is the centralized management department of the process (operation) accident, once the process (operation) accident occurs, the relevant department personnel should be organized in time to conduct the investigation and analysis, and at the same time evaluate the hazard of the accident, that is, the direct economic loss caused by the accident. ? What is the indirect loss, which production units are affected, the scope and personnel involved, and the seriousness of the consequences if the accident is expanded? If you find an abnormality and take decisive measures in a timely manner, etc., carefully analyze and evaluate the problem.

In short, production process safety technology management is an important part of enterprise safety management, and it is the key monitoring link of safety management, especially the control of key safety process indicators. If the safety management of the production process is completed, other accidents will be reduced accordingly, ensuring that the production facilities will continue to operate steadily, and that economic and social benefits and the survival and development of the enterprise will be discussed.

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